950-CONDENSATE COVER 14/6/99 10:23 am Page 3

PUROLITE TECHNICAL BULLETIN

C O N D E N S AT E
P U R I F I C AT I O N
The Influence of Operating Conditions on
the Ion Exchange Processes
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CONTENTS

1 INTRODUCTION Page 2

2 T H E N E E D F O R C O N D E N S AT E P U R I F I C AT I O N P L A N T Page 2

3 CONDITIONING CHEMICALS Page 2

4 WAT E R Q U A L I T Y R E Q U I R E D Page 3

5 FA C T O R S A F F E C T I N G T H E P E R F O R M A N C E O F

C O N D E N S AT E P U R I F I C AT I O N P L A N T Page 3

5.1 Flow Rate Page 4

5.2 Regeneration Procedures and Conditions Page 5

5 . 3 C o m p o s i t i o n o f W a t e r t o b e Tr e a t e d Page 7

5.4 Mixed Bed - Cation Resin in Hydrogen Form Page 7

5.5 Mixed Bed - Cation Resin in Ammonium Form Page 8

5.6 Use of cation resin when treating amine dosed condensate Page 9

5.7 Filtration Page 10

5.8 Use of Powdered Ion Exchange Resins Page 10

6 CONCLUDING COMMENTS Page 11

6.1 Purolite Performance information Page 12

Index Page 16

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1 INTRODUCTION
The term 'condensate purification' is normally applied to the
treatment of condensed steam from turbines operating in the
power industry. For once through boilers, both nuclear and
fossil fuelled, or high heat flux boilers such as oil fired coastal
stations, the whole of the condensate flow is likely to be treated
in an additional plant to that used to provide the make-up water
supply. Partial condensate purification facilities may be provided
on large conventional coal fired plants, but in this case, the final
stage of the make-up water treatment plant will be suitably sized
to treat, typically, up to 25% of the feed flow to the boiler for
short periods i.e., during start-up when contaminants in the
system are most likely to be present.
In this publication, factors affecting the performance of full-flow
condensate purification plant (CPP) are examined with particular
attention to the functions of the ion exchange resins.
2 T H E N E E D F O R C O N D E N S AT E
P U R I F I C AT I O N P L A N T
Why is it necessary to treat condensate which may already be in
a high state of purity? There are several reasons, but the most
outstanding need arises from the fact that traces of soluble
impurities present in the feed water entering a high pressure
boiler can be concentrated within the system. The degree to
which this occurs depends on the design of boiler, heat flux,
oxide thickness at heat transfer surfaces, and the level of
insoluble impurities. For example, concentration factors as high
as 104 to 106 can arise at local sites within drum boilers: this
means that g/kg quantities of impurities or even lower can
concentrate up to mg kg-1 levels.
In a once-through type of boiler all the water entering a tube is
evaporated in a single pass and salt concentration occurs at the
water/steam transition point. The result of these concentration
mechanisms is that there is a risk of corrosion of boiler tubes by
ions such as chloride and sulphate, and if failures occur the eco-
nomic penalties are very severe.
A special situation arises with once-through boilers operating
under supercritical conditions, i.e. such that the critical pressure
(221 bar) and temperature (374C) is exceeded and a single
phase fluid exists rather than two phase water/steam conditions.
In this case, all the impurities in the boiler fluid will be present as
the fluid enters the turbine. Consequently, there is a subsequent
risk of substances depositing within the turbine. At the
temperatures and pressures involved this includes metallic
elements like copper and iron which have an appreciable
solubility under the boiler conditions which reduces rapidly as
the fluid passes through the high pressure section of the turbine
Page 2
and can lead to the formation of hard, tenacious deposits,
resulting in a deterioration in output from the turbine.
It follows that under these conditions the condensate purifica-
tion plant has to be capable of removing copper and iron (solu-
ble and insoluble species) to a very low concentration.
There are various potential sources of soluble contaminants into
the water/steam circuits of power plants:
Cooling water from condenser in-leakage and this can
be a particularly severe problem where sea water cooling
is employed.
Make-up water, this can arise from maloperation such
that regeneration chemicals enter the system, the plant
may over-run during the service cycle or complete
removal of certain substances such as organic matter
may not occur.
The conditioning chemicals used to protect the circuit
e.g. ammonia, morpholine and hydrazine can be regarded
as sources of contamination if they are to be removed by
the condensate purification plant.
Insoluble impurities will usually be the corrosion products from
the materials in the system. Copper and iron are the
predominant species and hence they are usually included in the
water quality specification. However, under commissioning
conditions a number of other substances, in particular, silica
from lagging and cementitious materials, may be present in
insoluble form.
It follows from the foregoing that a condensate purification plant
needs to be capable of removing both soluble and insoluble
species to very low concentrations. Ion exchange resins can
fulfil both requirements, but additional filtration, pre-coat or
deep bed, have frequently been incorporated.
3 CONDITIONING CHEMICALS
Protection of the feed and boiler circuits in power plants
employing condensate purification plant is provided by the
addition of ammonia, to elevate the pH, and hydrazine, to
remove any residual dissolved oxygen present.
The aim is to control pH between 8.8 - 9.6 with the actual pH
being set by the particular site operating conditions. Normally a
pH range of 8.8 to 9.2 will protect the system and minimize the
transport of metallic impurities from the feed circuit to the
boiler. However, should there be a risk of erosion/corrosion
occurring it may be necessary to raise the pH to 9.4 or above. It
should be noted that increasing the pH level can have a
significant effect on the design and operation of CPP.
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For example, the ammonia concentration has to be increased by with the overall aim of achieving a balance of ions to provide
a factor of 4 to raise the pH from 9.2 to 9.6. Consequently, this neutral conditions at the heat transfer surfaces.
will increase the load on to cation sections of the plant by the
same factor, thereby increasing the regeneration frequency. A similar standard was subsequently adopted for CPP on Super-
critical and early gas cooled nuclear stations.
Alternative volatile amines such as morpholine and AMP (2
amino - 2 methyl propanol) may afford better protection than Meanwhile, operating experience was showing that PWR
ammonia, particularly where there is a risk of erosion/corrosion stations were suffering from corrosion due to the use of relatively
occurring. By providing improved pH conditions in the water poor quality water. High concentration factors of impurities
phase of the two phase (steam/water) region of the boiler [1]. occur in PWR steam generators, consequently the feed (CPP)
quality needs to be compatible with these conditions. This has
The use of these alternative amines will affect the operation and resulted in an even more stringent water specification being
performance of the CPP designed to work under normal pH applied to the quality of treated water to be supplied to PWR
conditions using ammonia, as higher concentrations are needed plant as follows:
than with NH3, to achieve a given pH. Further details on the
particular factors involved in operating CPP in this mode are Conductivity <0.06 S/cm at 25C
given in Section 5.6. Chloride <0.3 g/kg
Sulphate <0.5 g/kg
The use of hydrazine generally poses no problems to the CPP. Sodium <0.3 g/kg
The breakdown products are mainly ammonia, from high Silica <4 g/kg
temperature degradation, and nitrogen from the reaction with
In addition to the above, low concentrations of iron and copper
any oxygen in the water.
have to be maintained in the feed water to any high pressure
power plant to minimise corrosion in the boiler and to prevent
deposits in the turbine. Accordingly, a CPP has to be capable of
4 WAT E R Q U A L I T Y R E Q U I R E D producing water of very low iron and copper content.

Consideration of the quality of water required to be produced by The quality demanded will depend upon the specific type of
CPP is closely related to developments that have occurred in plant to which the CPP is being applied. However, usually the
CPP design over the years. standard required is that frequently specified for the feed water
quality to H.P. boiler plant, i.e. total iron < 5 g/Kg: Total copper
The original specification for water quality from CPP on super- < 2 g/Kg.
critical fossil fuelled units was:
The combination of filtration and ion exchange capability within
Conductivity 0.1 S/cm at 25C a CPP normally ensures that these limits are achievable.
Sodium <5 g/kg
It can be seen from the above that, progressively, a higher qual-
and with the advent of AGR nuclear stations this specification
ity water has been demanded from CPP. The following sections
was used initially. However, investigational work had shown that
will show how these requirements have affected the design and
the AGR gas side conditions at the boiler tube surfaces in the
operation of CPP, and the choice of ion exchange resins.
evaporator sections could give breakaway oxidation. To prevent
this occurring operating procedures had to be changed, but this
introduced an increased risk of corrosion occurring within the
water side of tubes. It was realised that minute traces of acidic 5 FACTORS AFFECTING THE
sulphates could be present in water from a CPP, particularly in
P E R F O R M A N C E O F C O N D E N S AT E
the period immediately following a regeneration. Calculations
were made on the concentration factors likely to arise in the P U R I F I C AT I O N P L A N T
boiler and these were used to indicate the quality of water
required from the CPP to protect the system from pitting corro- A CPP has to produce the quantity of treated water required to
sion of ferritic steels and stress corrosion of austenic materials. the water quality specification at all times and this will include a
Accordingly, a more stringent water quality was set as follows: variety of operating conditions. The ability of the plant to meet
this requirement is dependent on both the design and operating
Sodium 2 g/kg
conditions, and how these might affect the ion exchange
Chloride 2 g/kg
process has to be a prime consideration. The performance and
Sulphate 2 g/kg
life of the ion exchange resins used might be affected,
Conductivity <0.08 S/cm at 25C

Page 3
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Fig 1. Typical Condensate Purification Plant with

Mixed Beds

CONDENSATE

RESERVE
CHARGE
MIXED MIXED MIXED OF RESIN
BED BED BED

RESIN TRANSFER

TREATED WATER REGENERATION PLANT

TO FEED SYSTEM (ONE OR TWO VESSELS)

RESIN TRANSFER

RESIN TRANSFER

CHEMICAL STORAGE
DILUTION AND
MEASUREMENT
EQUIPMENT

consequently, the choice of resins needs to be closely related to
the plant factors.
The main factors involved are:
Flow rate
Regeneration procedures and conditions
Composition of water to be treated
Quality and quantity of treated water to be produced
Fig.1 shows the layout of a typical CPP plant.
these individual effects could be reduced in magnitude, but,
unfortunately, in minimising one effect the other adverse effect
might be accentuated. For example; pressure drop depends on
flow rate and particle size, hence in using larger beads a lower
pressure drop can be obtained. (The differential pressure is
inversely proportional to the square of the particle size:
therefore, if the particle size is doubled the differential pressure
decreases by a factor of four!). However, the use of large beads
proportionately decreases the surface area available for lon
Exchange and would result in slower kinetics and a consequent
risk of obtaining a poorer quality water with reduced capacity.

5.1 Flow Rate

Under normal condensate polishing conditions a high service
A CPP has to be designed to filter and deionise large quantities
flow rate alone is unlikely to result in a serious physical break-
of water. For a 660MW PWR unit, in the region of 1500m3/h of
down of the cation and anion resins. However, the resins can be
treated water has to be produced. Hence to minimise the capital
weakened by other factors, such as the osmotic stresses that
cost of plant the ion exchange beds have to be operated at a
arise during regeneration, and high flow rate plus resin transfer
high flow rate relative to normal ion exchange plant, and in the
are then additional factors that may lead to subsequent physical
case of the mixed beds these are generally designed to operate
breakdown.
at a specific flow rate of 100 - 150 m/h (m-3m-2h-l)

The major influence of a high flow rate is to decrease the time

High flow rates can result in two main effects:
Increased pressure drop, with a consequent increase in
the risk of physical breakdown of resin.
Decrease in the time for the lon Exchange reactions to
occur.
By choosing particular types and particle sizes of resin, each of
available for the ion exchange reactions to occur as condensate
passes through a bed, and hence the kinetics of the ion
exchange resins become more critical properties [7-13].
The overall rate of exchange is determined by a number of
chemical and physical factors:

Page 4
638-CONDENSATE TEXT 14/6/99 10:27 am Page 7
diffusion of ions across the static film of water at the
surface of a bead
diffusion within a bead
particle size of beads (surface area)
exchange of ions onto the active groups of a resin
types of ion present
pH conditions within the bed.
For the highly ionised cation and anion resins used in CPP, the
rate of exchange of ions within the active groups on the resin
will be high, and the overall rate controlling factor will be the rate
of diffusion across the static film of water at the surface of a
bead. This always applies even when the resins are new.
However, in service, deterioration in the performances of the
resins may occur due to fouling and/or ageing. In this respect
anion resins are more susceptible than cation resins. They are
more likely to receive fouling species e.g. organic matter which
could arise from a number of sources including sulphonates from
the cation resin. Moreover, they are chemically less stable than
cation types and some degradation of the strongly basic
groupings will inevitably occur. It has been shown [10-14] that
those effects result in poor anion exchange kinetics at the
surfaces of the beads and thereby, the rate of exchange of ions
at the surface then controls the overall rate of exchange.
The rate of exchange will differ for differing types of ions, but at
the relatively low flow rates used in make-up water treatment
plant such differences are rarely observed for inorganic ions.
However, the difficulty encountered, on occasions, in satisfactorily
removing organic species can at least be partially attributed to
kinetic factors.
At the much higher flow rates used in modern CPP even the dif-
ferences in the rates of exchange of inorganic ions become
observable in practice. In particular, the sulphate exchange is
slower than chloride exchange. The rate difference is of little
practical significance when new resins are in use. However, as
indicated above, deterioration in kinetics due to fouling/ageing
occurs with time and results in an overall slower removal of these
anions; furthermore, the low rate of uptake of sulphate relative to
chloride ion is enhanced.
In recent years, a number of investigations on anion kinetics
have been reported and fuller details relative to the above can be
obtained from references [7-13]. The present position can be
summarised as follows.
At the high flow rates used in mixed bed operations the anion
resins are working near to the limits of their kinetic ability. The
zone of exchange, which is the depth of bed required to produce
the desired quality of water, is a significant proportion of the total
bed depth. It follows that any deterioration, in service, of the
kinetic ability will result in an increase in the length of the zone
with two possible adverse effects.
Page 5
The quality of water required may not be obtained.
The capacity of the resin for treating condensate
contaminated with cooling water will be decreased.
(See also Section 5.2 and 5.4)
5.2 Regeneration Procedures and Conditions
Regeneration of the ion exchange resins within the service
vessels is not practicable owing to the wide variations in service
and regeneration flow rates and the need to eliminate the risk of
directly contaminating the water/steam circuit with the regener-
ation chemicals used (sulphuric acid or hydrochloric acid and
sodium hydroxide). Consequently, in early CPP the resins were
transferred from the service vessels to a single regenerator
vessel, and the cation and anion resins were separated and
regenerated in this vessel.
It is of vital importance that cross contamination of the resins by
the wrong regenerant should be minimised hence the separation
of the cation and anion resin components is a crucial stage in the
regeneration procedure. Whilst the slight contamination of cation
resin with sodium hydroxide when operating in the hydrogen
form is undesirable, it is relatively unimportant when compared
with contamination of the anion resin with sulphuric or
hydrochloric acid which can result in difficulty in obtaining the
required sulphate or chloride concentration in the treated water
following regeneration.
The following equations illustrate how this arises (sulphuric acid
regeneration).
1 RN+ (CH3) 3OH- + HSO4-RN+ (CH3)3 HSO4- + OH-
2 2 (RN+(CH3)3 HSO4)- + H20(R N+(CH3)3)2 SO4-- + H2SO4
Anion resin contacted by the sulphuric acid is converted to the
bisulphate form (equation 1).
Subsequently when the resins are mixed and the final rinsing
begins, the bisulphate form resin is converted into the sulphate
form with the release of sulphuric acid (equation 2). This sulphate
then has to be taken up by the bulk of the anion resin in hydroxyl
form. With new anion resin this can be done, but it has been
shown [2] that any deterioration in the kinetic performance of the
anion resin due to fouling/ageing will result in the need for pro-
longed rinse periods before satisfactory sulphate concentrations
can be obtained. The rate of uptake of sulphate ions by the anion
resin is too slow so that there is not enough time for the sulphate
released from a portion of the bed near to the bottom of the unit
to be removed to the desired level before the water leaves the
bed. The depth of this zone dictates the extent of the prolonged
rinse requirement, and the depth will depend on the kinetic
condition of the anion resin. For new resin a very short zone will
exist, but this will increase progressively with any deterioration in
the kinetic performance of the anion resin.
638-CONDENSATE TEXT 14/6/99 10:27 am Page 8
(Note that this problem can be partially ameliorated by allowing
the mixed bed to stand for a period prior to return to service.
However, this may not be possible on a short cycle designed plant or
in the event of a severe condenser leak).
From the above it follows that the cation and anion resins need
to be of suitable size and density to allow good separation to
occur on backwashing.
A range of cation and anion resins combinations may be used
and in general optimum separation will be achieved with cation
resin of 0.7 -1.2mm and anion resin of 0.42 - 0.85mm. The ideal
effective particle sizes would be 0.8mm and 0.55mm for the
cation and anion resins respectively.
Density differences are enhanced by using a gelular cation resin
of high DVB (10%) and a macroporous anion resin, but there is a
need to establish that this combination would be of adequate
physical strength.
An inert material of intermediate density and particle size has
been used to provide an additional buffer between the cation
and anion resins and reduce resin cross contamination.
Unfortunately on occasions difficulties have arisen due to the
susceptibility of such materials to oils, greases and metal
oxides: consequently they are unable to act consistently as
satisfactory buffers in CPP.
Details of typical chemical and physical characteristics of a
range of resins suitable for use in CPP mixed beds are given in
Appendices 1-4.
In addition to using resins having optimum separation character-
istics plant modifications have also been made to improve the
regeneration process to reduce the risk of cross contamination
arising, examples being:
Separate Cation - Anion Regeneration Units
One of the first modifications/improvements to condensate
polishing regeneration systems was to employ, instead of a
single regenerator, separate cation and anion regeneration units.
Providing good separation could be achieved there was less
chance of regenerant cross contamination and each regenera-
tion unit could be specifically designed to give more freeboard
for vigorous back-washing and air scouring. This is particularly
important for a naked mixed bed which also acts as a filter.
Originally the mixed bed resins were backwashed in the cation
regenerator to separate the mixture into the two components.
Then via sluicing nozzles located at the resin interface in the
cation regeneration/separation unit the anion resin was sluiced
off the surface of the cation resin into its own regeneration unit.
While this system is used worldwide it has obvious limitations in
Page 6
that it relies on the interface being always located at the exact
position of the sluicing nozzles. This is not always possible to
guarantee and hence excessive cross contamination can occur.
Further improvements were obviously required.
CONESEP- NEI Thompson Kennicott [4]
Fig 2. The Conesep System
INTERFACE
ISOLATION
VESSEL
SEPARATION
/ANION
REGEN.
VESSEL CATION
REGEN.
VESSEL
CONDUCTIVITY
CELL
Fig 2 shows a diagram of plant.
The mixed bed is transferred from the service vessel to the main
separation unit which also serves as the anion regeneration
vessel. On backwashing, the resins separate and the lower
cation resin layer is then hydraulically transferred to a separate
vessel simply by introducing water into the base of the Conesep
vessel and forcing resin to flow out through a transfer pipeline.
During this transfer the anion/cation resin interface descends
smoothly through the vessel, the base of which is cone-shaped
to compress the interface, and eventually enters the transfer
pipeline. In this pipe it is sensed by conductimetric or optical
means and the transfer terminated. On the original full scale
installation this procedure results in cation and anion cross
contamination figures of about 0.3% v/v. [4].
The level of cross contamination is acceptable for plants aiming
to produce water with sodium levels of less than 0.1 ppb when
operating in H-OH mode.
Variations introduced since the design was first used include
adjustments to the all important base design, the development
of alternative interface sensing techniques and the development
of a secondary separation stage. This involves a secondary
classification, by backwashing, of the anion resin component
after its regeneration with sodium hydroxide. This second sepa-
ration relies on the fact that any cation resin beads in the anion
resin are now in the more dense sodium form. Thus they are
more easily separated from the anion resin which is now in the
less dense OH form.
The small amount of cation resin recovered by this procedure is
638-CONDENSATE TEXT 14/6/99 10:27 am Page 9
moved to an interface isolation vessel and subsequently added
to the next charge to be regenerated.
These improvements have particular benefit to operation in the
ammonium or amine cycle when the cation resin in the mixed
bed has to have a very low residual sodium content. Separation
down to <0.06% v/v of cation resin in anion resin has been
achieved on fullscale operating plant, [5].
TRIPOL- PWT Projects Ltd
In this type of plant the resins are not used as a mixed bed but
are separated by screens into three layers cation - anion - cation
[6] as shown in Fig 3. The resins are transferred from the service
vessel for regeneration.
The cation and anion resins are kept apart in the regeneration
system, even to the extent of having separate resin movement
lines so that the cross contamination problem of the wrong
regenerant on the resin is completely avoided. Resin ratios and
volumes can be altered to suit particular operating conditions
but typically the lead and trail cation are each 350mm deep, and
the anion 500mm deep. The linear flow rate is typically 200m/h
and the separated beds techique avoids the compaction which
occurs in a deep mixed bed so that the headloss is about the
same as a classic mixed bed condensate polishing plant running
at 120m/h.
TRIPOL CATION ANION
OPERATOR REGENERATOR REGENERATOR
DILUTE ACID DILUTE CAUSTIC
CONDENSATE
INLET
LEAD CATION
ANION
TRAIL CATION
CONDENSATE OUTLET
Fig 3. The Tripol Process
The process is not sensitive to resin type or indeed particle size.
Both macroporous and gelular cation and anion resins have been
used successfully although to achieve the best possible capaci-
ty under arduous conditions the usual recommendation is for a
10% DVB cation resin gel, and one of the modern high strength
high capacity gel anion resins.
During the original development of the process it was observed
that single beds of resins both cation and anion can exhibit bet-
ter kinetics than occur in a mixed bed and these findings have
been reported in detail [13]. Practically, this allows larger beads
Page 7
of resin to be used without affecting the kinetics and also result-
ing in a lower headloss.
In the USA, two other processes are used to overcome cross
contamination of the resins by the regenerant chemicals as follows:
AMMONEX - Crane Cochrane
The process was developed specifically for operating conden-
sate purification plant with the cation resin of the mixed bed in
ammonium form. Two regenerator vessels are used. Following
transfer from the service vessels separation is carried out by
back-washing. The anion portion is then transferred to the
second regenerator and in this stage the resin transfer point is
usually biased towards the anion section in order to limit the
quantity of cation transferred with the anion resin. The anion
resin is then regenerated with sodium hydroxide and rinsed.
Ammonium hydroxide is then passed through the bed to convert
any cation resin present from the sodium to ammonium form.
Meanwhile the main cation section is regenerated with sulphuric
acid and rinsed. The cation and anion resins are then mixed.
Subsequently, the bed may be ammoniated either externally or
during the service cycle.
SEPREX- Ecodyne Graver
In this system the resins are transferred from the service vessel
to the first of two regeneration vessels. The resins are then
separated by backwashing and the anion portion is transferred
to the second vessel. After draining water from the anion resin, a
16% solution of sodium hydroxide is applied, this enhances the
separation by floating the anion resin from any traces of cation
resin that have been carried over. The anion resin is then taken
from the vessel to the third vessel for rinsing. The cation resin
remaining is rinsed and transferred to the main cation regenera-
tion vessel for mixing with the next charge of cation resin to be
regenerated.
The main cation bed is regenerated and rinsed in vessel one
prior to the transferring to the third vessel for mixing with the
anion resin in readiness for use.
5.3 Composition of Water to be Treated
As indicated in Section 3, the condensate to be treated can
range in pH from 8.8 - 9.6 and this represents ammonia
concentrations of up to 2.2mg/Kg NH3 of water. In addition, in the
event of a condenser leak salts from the cooling water, usually
mainly chloride from sea water, will be present. Additionally, sul-
phate can be present in the mixed bed following a regeneration.
5.4 Mixed Bed - Cation Resin in Hydrogen Form
The majority of plants operate with the cation resin in hydrogen
form and the end point of a service cycle, in the absence of
condenser leakage, is a break through of ammonia, whether it be
from a cation preceding a mixed bed or from a mixed bed
working alone.
638-CONDENSATE TEXT 14/6/99 10:27 am Page 10

For a condensate of high pH the load on the cation resin is high
and a resin is required which combines a high capacity for
ammonia with a satisfactory resistance to attrition.
The capacity obtained will depend on:
The level of regeneration
The breakpoint chosen
The degree of cross linking of the resin (DVB content)
Ammonium ion capacity determinations made on fullscale cation
units have given a range of results from 0.7 -1.2 eq/l of resin.
This range is at least partially due to the differing hydraulic con-
ditions in large diameter beds giving variation in the uniformity of
flow.
In the event of a condenser leak the loading onto the cation resin
will increase due to the ingress of sodium, but the inherent
capacity of the resin is not affected significantly and the run
length to exhaustion can be estimated solely from the increased
cation load.
The foregoing indicates that for CPP, as opposed to make-up
water treatment plant, accurate operating capacity of the anion
resins is difficult to specify. Historically, a figure representing
25% of the total volume capacity of the resin has been used in
design calculations to estimate the time the bed could operate
with a specific condenser leak. It is difficult to obtain accurate
data on anion capacity from plant tests, but the indications are
that even the 25% figure is increasingly difficult to achieve as the
anion resin kinetics deteriorate. Capacities as low as 10-15%
have been obtained under condenser leakage conditions on
operating plants.
5.5 Mixed Bed - Cation Resin in Ammonium Form
Ammonium used to condition the water in feed and boiler
systems represents the main load onto a cation resin operating
in hydrogen form, and the higher the pH control level the greater
the load. This is a disadvantage in that it leads to the need to
regenerate the cation bed and or the mixed bed on a frequent
basis. Regeneration of the mixed bed has attendent problems in
relation to maintaining satisfactory sulphate levels.

By operating the cation resin in ammonium form, ammonia in the

From capacity considerations a standard 8% DVB gelular resin
feed water is not removed, but adventitious cations such as
would be the preferred choice, but such a material is not suffi-
sodium and calcium can be taken up by the resin. However, the
ciently robust. An optimum choice would be the 10% DVB
difference in selectivity of ammonium and sodium ions is slight
Purolite SGC100 x 10 gelular resin, which has high physical
so that the sodium content of the resin has to be maintained at
strength and a capacity for ammonia in the range of 1.2 -1.7
a very low concentration to obtain satisfactory low concentration
eq/l.
of sodium in the treated water from the bed. The most suitable
resin under these conditions is one which has a high selectivity
Usually, the removal of anions from condensate takes place solely
for sodium relative to ammonium and has adequate physical
within mixed beds. The exception is where a Tripol plant is
properties. Available data indicate that selectivity differences
installed and a separate anion section is present.
with increased cross linking (DVB content) are slight therefore
the choice can be made on the basis of satisfactory physical
For a number of reasons, it is more difficult to predict the oper-
properties and cost. Purolite SGC100 x 10TL and Purolite
ating capacity of anion resin in CPP. In addition to factors such
C150TL are typical resins suitable for use under these conditions.
as the uniformity of flow conditions, the low concentration of
anions to be removed and the high quality of product water
The capacity of cation resin in ammonium form depends upon
required, anion resin kinetics will play a major role in determining
the concentration of sodium present usually as the result of
both quality of water produced and the capacity for dealing with
condenser leaks. The selectivity coefficient KNa/NH4 = 0.77 is
condenser leaks.
lower than KNa/H = 1.7 hence the resin will have a lower capacity
for sodium when operating in the ammonium form and more
The deterioration of the kinetics of anion resin is likely to have
importantly the concentration of ammonium ion present results
the greatest influence on the capability of a bed for coping with
in the equilibrium leakage of sodium being high relative to hydro-
condenser leaks. However, it must be emphasized that hydraulic
gen exchange. For example the concentration of sodium on the
factors such that non uniform uptake of ions occurs within the
cation resin at the bottom of a bed cannot exceed 0.1% when
bed could have an over riding effect as the beds are shallow
treating a water pH 9.6 if a level of 2 g/kg sodium is to be
relative to the diameter of the vessels employed.
obtained in the treated water. It follows that the capacity of
ammonium form resin for sodium will be much lower than when
It is debatable whether in the short term, resins could be
operating in the hydrogen form. The equilibrium conditions for
produced having superior kinetic properties which could be
sodium/ammonium exchange lead to a longer exchange zone
maintained for a longer period than the present products, and at
than for sodium/hydrogen exchange and hence a lower capacity.
present in some situations regular changing of the anion resin
The actual capacity obtained will depend on the concentration
probably represents the best economic option. Nevertheless,
present in the water being treated, the greater the concentration
efforts are being made continuously to improve the overall
the greater the capacity.
performances of anion resins.

Page 8
638-CONDENSATE TEXT 14/6/99 10:27 am Page 11
In [15] figures are given of 7 eq m-3 at an inlet of 5 g/kg Na and
up to 150 eq m-3 at 350 g/kg Na when treating condensate at
pH 9.6 and working to a 2 g/kg Na breakthrough point.
The pH conditions within a mixed bed operating with the cation
in ammonium form will be those of the condensate i.e., 9.0 - 9.6.
It has been shown that anion exchange rates are slower at these
high pH's relative to hydrogen form cation operation [7]. The
zone of exchange is extended and therefore a higher kinetic
leakage of chloride and sulphate ions and a lower capacity
would be predicted for the anion resin relative to when hydrogen
form cation resin is used under comparable conditions.
Nevertheless, data reported [15] on the performance of anion
resin used in a Tripol plant operating in the ammonium form,
indicates that under high simulated condenser leak conditions a
capacity equivalent to 30% of the total volume capacity of a
macroporous anion resin was obtained. This in part may also
reflect the better hydraulic conditions for anion exchange in
such a plant relative to mixed beds.
5.6 Use of Cation Resins when Treating Amine
Dosed Condensate
As mentioned in Section 3, amines other than ammonia may be
used to protect nuclear systems from corrosion. To obtain the
required pH conditions relatively high concentrations are needed
i.e., at Oldbury Power Station in the U.K., morpholine levels in
the range of 6-30 mg/kg have been used [1].
Experience with CPP plant treating condensate dosed with
amines has shown that there is a risk of breakdown of macrop-
orous cation resins [16] and that the degree of breakdown is
dependent on the DVB content of the resin. The higher the DVB
content the greater the risk of breakdown.
Laboratory tests showed that the breakdown arises from the
osmotic forces present when an amine form resin is regenerated
with acid, and that this effect is significantly enhanced by any
contact between the resin and sodium hydroxide used to regen-
erate the anion resin. The tests showed that 20 and 25% DVB
macroporous resins were particularly susceptable to breakdown,
whereas 10% DVB gelular resin and 12% macroporous resin
were virtually unaffected.
The following factors need to be considered in choosing the type
of resin to be used when treating amines dosed condensate:
Physical stability
Sodium/amine selectivity
Resin separation (density/particle size)
Capacity/acid requirement for regeneration
We examine the following factors for several operating conditions.
Page 9
H Form Operstion
Under these conditions the physical strength and separation
characteristics are likely to dictate the choice of resin.
Selectivity differences between resins are slight and can be dis-
counted. Both 10% gel or 12% macroporous cation resins could
have satisfactory resistance to breakdown. However, the gel
resin will also have enhanced separation characteristics due to
its slightly higher density relative to a macroporous type.
Additionally, it would also be expected to have a higher operat-
ing capacity.
Morpholine Form Operation
In this case, the presence of morpholine in the treated water
affects the equilibrium leakage of sodium from the mixed bed.
The leakage values depend on the selectivity coefficient
Na
K morpholine of the cation resin and the sodium content of the
resin.
Now the data in Ref 16 indicates that the selectivity coefficient
increases with DVB content and hence to minimise sodium leak-
age a resin of the highest possible DVB content should be used.
From selectivity considerations, therefore, a 20% DVB resin
would be preferred when operating with morpholine. However,
the risk of breakdown of this material is high and clearly out-
weighs its potential advantage on selectivity grounds.
If we then consider the 12% DVB resin which would have
adequate strength we find that it has a much lower (factor of 20)
selectivity coefficient than the 20% DVB material, and is only a
factor of two higher than that of a 10% gel resin (which also has
a satisfactory physical strength). It follows that there will not be
an outstanding difference between the 10% gel and the 12%
macroporous resin in terms of equilibrium leakage of sodium.
The sodium content of the resin is dictated by two main factors.
The quantity of cation present in the anion resin after
separation which is subsequently in contact with sodium
hydroxide.
The level of sodium remaining on the separated cation
resin after regeneration.
Separation procedures such as described earlier should be
capable of ensuring that a satisfactory low level of cation in
anion resin is obtained in the absence of breakdown of cation
resin.
However, if breakdown of the cation resin occurs with the
production of small fragments of beads it could be then increas-
ingly difficult to effect the required degree of separation. It
follows that physical stability must be a prime consideration,
and hence when choosing between a 10% DVB gel and 12%
DVB macroporous resin a critical factor will be their relative
resistance to physical breakdown.
638-CONDENSATE TEXT 14/6/99 10:27 am Page 12
This needs to be established in respect to products currently
available. Additionally, individual batches of resin supplied for
this application should be tested under simulated operating
conditions.
2 Amino - 2 Methyl Propanol Form Operation
Similar conditions and considerations apply to those for
morpholine form operation, but for AMP operation the selectivity
coefficient [16] for the 12% DVB macroporous resin is a factor of
5 higher than the 10% gel resin. Hence, it is possible that a lower
level of sodium leakage might be obtained with a 12% DVB
macroporous resin, but the selectivity advantage might be
partially affected by the greater difficulty in removing sodium
from the 12% DVB resin during regeneration compared with the
10% material.
There is a need to establish the quality of water in terms of
sodium leakage, likely to be obtained with these resins under
conditions which accurately simulate plant conditions. This data
together with that from the long term comparative physical
stability tests mentioned in [16] should allow the correct type
of cation resin to be chosen for operating under AMP form
conditions.
5.7 Filtration
The water/steam circuit of power plant may be contaminated by
insoluble corrosion products such as iron and copper. This
occurs mainly during initial commissioning when concentrations
of iron as high as 2000 g/kg can be experienced. Subsequent
high levels of debris are likely to be present only during start-
ups, when the system is disturbed. At this time concentrations of
100 - 200 g/kg may arise. During normal load operation total
concentrations will usually be <5 g/kg.
In older CPP, filters of various types were included prior to the
ion exchange section. In subsequent designs, however, the ion
exchange beds had also to act as filters. If a cation bed
precedes the mixed bed this obviously acts as the main stage of
filtration. In some cases, pre-coat filters are provided to operate
either before or after the mixed bed unit.
A deep bed exchange unit acts as an efficient filter and depending
on the inlet concentration of debris, 70 - 90% removal of debris
is obtained. Particle size of the debris will dictate the degree of
removal achieved. The debris can be satisfactorily removed from
the bed by air scouring and backwashing.
There is no evidence that the type of resin used i.e., gelular or
macroporous, affect the filtration efficiency.
5.8 Use of Powdered Ion Exchange Resins
Pre-coat filters have been adapted for use with powdered lon
Exchange resin. A thin film of powdered cation and anion resins
is formed onto the outside of a hollow cylindrical element. A
Page 10
variety of designs of elements exist but usually they comprise of
filters wound onto a perforated stainless steel former. The liquid
to be treated flows inwards passing through the ion exchange
resin material and out to service.
When the resins are similar to those employed in deep bed ion
exchange. The particle size of the resin is approx. 30 micron and
when the cation and anion resins are mixed, a bulky floc forms.
The characteristics of the floc vary depending on the ratio of
cation/ anion resin used. To form the coat the mixed resin floc is
passed on to the element and water is circulated until a satis-
factory coat is obtained. The unit can then be put into service
and operated until either a specified increase of pressure differ-
ential is reached or up to exhaustion of ion exchange capacity.
The dry weight of the resins used to form the filter coat is equiv-
alent to 1 kg per m2 of element surface, and the usual service
flow rate is 100 - 200 m-2 min-1. The coat has a low resistance
to flow, and typical pressure differentials are 0.1 - 0.2 bar for a
freshly pre-coated unit. The unit can be operated to exhaustion
of ion exchange capacity, or to a specified pressure differential
(1.7 bar), if filtration is the main function.
When the end point is reached the spent resins are removed by
passing a flow of water in the reverse direction to that employed
during the service cycle.
The unit is then ready for recrating and the spent resins being of
no further value are usually discarded.
The powdered cation resin can be supplied in hydrogen and
ammonium forms, whilst the strongly basic anion resin is
supplied in hydroxyl form. Additionally the Purolite Microlite
powdered resins can be supplied already mixed in various
cation/anion ratios, and in the required ionic form. This has a
distinct advantage in the preparation of pre-coats. They can
also be provided with a proportion of fibre.
Powdered resin systems have been used widely in the USA and
Europe within condensate purification systems. In the USA they
are used in conjunction with deep mixed beds and alone.
However, their use alone is confined to stations where fresh
water cooling is employed and in the event of a condenser leak,
water of very low concentration relative to sea water enters the
system. This highlights the limited ion exchange capacity of the
process relative to conventional deep beds, and its main appli-
cation is therefore likely to be as a polishing treatment after a
deep bed or as a filter situated before a mixed bed.
Few powdered resin systems have been installed, for example in
the UK at one power station such units are situated down stream
of mixed beds, whilst in a sister station the units precede the
mixed beds. At both installations the powdered resin units can
be operated alone if required .
638-CONDENSATE TEXT 14/6/99 10:27 am Page 13
When installed after mixed beds, the main role of the units is to
provide an additional ion exchange facility in the event of a
premature breakthrough of the mixed beds, and to remove any
residual soluble impurities present after the mixed bed stage.
This could arise following the regeneration of a mixed bed, when
sulphate concentrations in the treated water can be higher than
in the middle of a service cycle. Under these conditions, the pre-
coat units are capable of maintaining sulphate concentrations in
the final treated water at <0.2 g/kg S04 throughout the service
cycle of a mixed bed.
Filtration may be the main function of a powdered resin system
if the units are installed to procede the mixed beds. This is
particularly useful during commissioning when high levels of
debris may be present.
As might be expected, powdered resins have excellent filtration
properties and even with high inlet debris levels the quality of the
treated water can normally be maintained at <5 ppb. However,
during periods when debris levels are high there will be a cost
advantage in using cheaper filter media such as cellulose fibre.
Such material can be used either along or in combination with
the powdered ion exchange resin. The Purolite product Microlite
FC is suitable for this application.
6 CONCLUDING COMMENTS
Three of the most frequently debated topics in respect to
condensate purification are:-
Whether to use mixed beds (or Tripol) alone or with a
preceding cation unit.
Whether to operate cation resin in ammonium, amine or
hydrogen form.
Types of resin which should be used.
It is useful at this point to consider the above from an ion
exchange viewpoint.
Mixed Bed Versus Cation Unit- Mixed Bed
An additional cation unit will usually be considered only when the
cation resins are to be operated in hydrogen form, and under
these conditions the cation - mixed bed system is to be
preferred from an ion - exchange function viewpoint.
The main advantages being:
i) a higher quality water is produced.
ii) a higher capacity can be obtained from the anion com-
ponent of the mixed bed.
iii) the system has a greater ability to cope with changes in
the pH of condensate.
iv) greater flexibility in the cation/anion ratio used in the
mixed bed.
Page 11
v) by reducing the number of regenerations of the mixed
beds, the potential mass of sulphate introduced into
the system should be less.
vi) an additional filtration facility is provided which may
also provide some protection to the mixed bed resins.
Note that it could be argued that a Tripol plant is in effect
operating with a preceding cation unit and that some of the
above advantages may also be realised, notably (ii) (iii) and (vi).
Hydrogen Versus Ammonium or Amine Form
Cation Resin in a Mixed Bed
The relative advantages of the two forms are:
Hydrogen Form
Kinetic leakage of anions will be lower.
Higher capacity under condenser leak conditions.
Resin separation conditions may not be so critical as
with ammonium form where superior regeneration
facilities such as provided by Conesep Ammonex or
Seprex are invariably required.
Should be able to meet the more stringent water quality
(0.3 g/kg sodium, chloride and 0.5 g/kg sulphate)
more easily.
Ammonium Form
The number of regenerations of the mixed bed will be
greatly reduced hence the risk of sulphate ingress into
condensate will be lower.
There is an obvious saving of both the condensate
conditioning chemicals and the resin regenerants.
Amine Form
As for ammonium form, but a greater cost saving in the condi-
tioning agent is achieved because a higher concentration of
amine has be used to achieve a given pH relative to ammonia.
Types of Resin For C.P.P.
Ideally resins for C.P.P. should have the following qualities.
HIGH
: resistance to osmotic shock and attrition (physical
strength)
: rates of reaction
: cation: anion separation characteristics
: capacities
: resistance to fouling
: thermal and oxidative stability
: uniformity of physical size
LOW
: resistance to flow (pressure loss)
: organic leachables content
638-CONDENSATE TEXT 14/6/99 10:27 am Page 14

Over the years a variety of different types of resin have been
used in CPP with varying degrees of success, frequently dictat-
ed by the plant operating conditions.
Resins have ranged from high DVB macroporous resins to low
DVB gelular resins, whilst the combinations of cation/anion in
mixed beds have ranged from gel: gel to macroporous: macrop-
orous.
publicity has been shown to be the most practical
when comparing test results with how resins actually
behave in plant operation. Consequently Purolite
installed this equipment both in their Quality Control
and Technical Service Laboratories under licence from
the Central Electricity Generating Board of the U.K. A
simplified diagram of the apparatus is shown in Fig. 4

In recent years Purolite has concentrated on improving the TABLE 1 PUROLITE RESINS FOR
physical strength of gelular resins to augment their advantage in CONDENSATE POLISHING
respect to separation characteristics and capacity. The higher
strength gelular cation resins are now commercially available UNIT OR SYSTEM RECOMMENDED PUROLITE RESINS
and have been shown under certain operating conditions to have
CATION UNIT Purolite C150C or SGC100x10C
greater resistance to physical breakdown than high DVB content
macroporous resins (5.6) Anion gelular resins of similar strength MIXED BED
have also been developed and will shortly be commercially (Including Conesep, Ammonex, Seprex)
available.
Cation H:OH operation Purolite C150TL or SGC100x10TL
NH4:OH operation Purolite C150TL or SGC100x10TL
Throughout this bulletin the author has attempted to illustrate
Amine: OH operation Purolite C150TL or SGC100x10TL
how the performances of ion-exchange resins can be affected by
a variety of operating conditions. Anion H:OH operation Purolite A500TL (or SGA400TL)
NH4:OH operation Purolite A500TL (or SGA400TL)
The examples provided are intended to show why the type of Amine:OH operation Purolite A500TL (of SGA400TL)
ion- exchange resin used often has to be a compromise between
TRIPOL
conflicting chemical and physical properties. The essential
Cation H:OH Purolite SGC100x10TL
requirement is for the resin to produce the quality and quantity of NH4:OH Purolite SGC100x10TL
water required at minimum operating cost. Amine:OH Purolite SGC100x10TL
Anion H:OH Purolite SGA400CL
6.1 Information Particular to the Performance of NH4:OH Purolite SGA400CL
Amine:OH Purolite SGA400CL
Purolite Ion Exchange Resins Recommended For
Condensate Polishing is Given as Follows:
PRE-COAT FILTERS
i) Table 1 shows the Purolite products recommended for Cation H:OH Microlite PrCH
various operations and appendices 1-4 gives the NH4:OH Microlite PrCN
properties of the individual resins. Anion H:OH Microlite PrAOH
ii) A separate set of graphs is given in fig 5 and fig 6 NH4:OH Microlite PrAOH
illustrating resin separation and hydraulic pressure Filter Fibre Microlite FC

drop respectively against flow rate for various resin

Specific Mixtures of above are: RATIOS
mixtures.
C/A
iii) In relation to normal acid regeneration levels a MB 1 to 1H Acid/Base H+/OH- 1/1
schedule of capacities is given in fig 7. MB 1 to 1N Acid/Base NH4+/OH- 1/1
iv) Bearing in mind the rigorous physical demands on MB 2 to 1H Acid/Base H+/OH- 2/1
resins used in Condensate Polishing, Purolite realised MB 2 to 1N Acid/Base NH4+/OH- 2/1
MB 3 to 1H Acid/Base H+/OH- 3/1
some years ago that a relevant test was required in
MB 3 to 1N Acid/Base NH4+/OH- 3/1
order to measure both the physical strength and the MB 3 to 2H Acid/Base H+/OH- 3/2
osmotic shock resistance of their resins in order to MB 3 to 2N Acid/Base NH +/OH-
4 3/2
ensure that the useful life was predictably long.
RATIOS
After examination of the various methods available on F/R C/A
OG-4H Acid/Base H+/OH- 1:1 1:1
an international basis it was decided that the method
OG-4N Acid/Base NH4+/OH- 1:1 1:1
defined by Ball, Harries and Pickering [17] in their OG-6N Acid/Base NH4+/OH- 2:1 2:1
paper presented at the Pittsburgh Water Conference OG-7H Acid/Base H+/OH- 1:2 3:1
1986 entitled "The Physical Strength of lon Exchange OG-12H Acid/Base H+/OH- 1:2 4:5
resins" was one of the most rigorous and since it's OG-12N Acid/Base NH +/OH-
4 1:2 4:5

Page 12
638-CONDENSATE TEXT 14/6/99 10:27 am Page 15

Essentially "categorised" resin samples are subjected to cycling Fig 5. Backwash - Resin Separation
with either acid (cation resin) or alkali (anion resin) with alterna- The figure below indicates backwash characteristics for a
tive treatment with sodium chloride. After each chemical cycle Purolite macroporous TL grade combination. For good separa-
the resin is hydraulically pumped against a top screen in the tion of the bed 100% expansion is required. At below 80%
attrition tube and allowed to drain back down to be ready for the expansion poor separation is likely.
next chemical cycle.
U.S. gmp/ft 2
Percent resin breakdown is then assessed after a cerain number 1 2 3 4
of cycles depending upon the generic category of resin under 120
110

Percentage bed bxpansion (%)

test. A BC D E
100 F
Table 2 shows breakdown percentage criteria that Puroiite fol- 90
lows in the manufacture of their various products. 80
70
TABLE 2 60
50
Standard gel Supergel Macroporus
40
C100 x 10 A 400 SGC100x10 SGA400 C150 A500 30
20
No of cycles 25 25 100 100 500 500
10
% Breakdown* < 10 < 20 < 10 < 10 <5 <5 5 10 15 20
Linear flow rate (m2 /m3 /h)
* As defined in test method by reduction in mean diameter.

A = 1:2 Cation - Anion ratio 20C

Fig 4. O.S.A. Test Apparatus
B = 1:2 Cation - Anion ratio 30C
C = 1:1 Cation - Anion ratio 20C
D = 1:1 Cation - Anion ratio 30C
E = 2:1 Cation - Anion ratio 20C
F = 2:1 Cation - Anion ratio 30C
TO CATCH POT CH 1 TO CATCH POT CH 2

For gel resin combinations allow 5-10% increased flow rate for
same bed expansion.
REGENERANT
EXHAUSTANT NON-RETURN EXHAUSTANT
NON-RETURN VALVES NON-RETURN Fig 6. Pressure Drop
VALVE VALVE
The figure below indicates pressure drop across Purolite TL
grade resins at Condensate Polishing Plant linear flow rates
ATTRITION
TUBES when clean. During plant operation the filtration of suspended
CHANNEL 1 CHANNEL 2 material and bed compaction will lead to increased pressure
loss. It is recommended that a margin of greater than 50% is
PULSE allowed in plant design. The exact pressure drop across the ion
VALVES
exchange bed will be dependent on condensate temperature,
crud loading and cycle length (bed compaction).

FAST SLOW FAST

DRAIN DRAIN
VALVES
DRAIN U.S. gmp/ft 2
VALVE VALVE
20 25 30 35 40 45 50 55 60
0.9
Pressure Drop per meter

SIEVE CH1 SIEVE CH2 3.5

of bed depth (kg/cm 2)

0.8
of bed depth (lb/ft 2 )
Pressure drop per ft

0.7 Gel resin 3.0

combination
DRAINAGE COLLECTOR 0.6 2.5
0.5 2.0
TO
DRAIN 0.4
0.3 Macroporous resin 1.5
combination 1.0
0.2
0.1 0.5

50 60 70 80 90 100 110 120 130 140 150

Linear flow rate (m2 /m3 /h)

Page 13
638-CONDENSATE TEXT 14/6/99 10:27 am Page 16

Fig 7. Cation Resin Capacities

Hydrogen Cycle Operation Hydrogen Cycle Operation

Purolite SGC-100x10TL Purolite C-150TL

Ammonia Cycle Operation Ammonia Cycle Operation

Purolite SGC-100x10TL Purolite C-150TL

The above capacities are based on dosed condensates.

Page 14
638-CONDENSATE TEXT 14/6/99 10:27 am Page 17

PUROLITE SGC-100x10TL PUROLITE C-150TL

(Clear Gel Strong Acid Cation Exchange Resin) (Macroporous Strong Acid Cation-Exchange Resin)

Typical Chemical & Physical Characteristics Typical Chemical & Physical Characteristics

Polymer Matrix Structure Gel Styrene- divinylbenzene Polymer Matrix Structure Macroporous Styrene- divinylbenzene
Physical Form and Appearance Clear amber spheres Physical Form and Appearance Pale-brown opaque spheres
Whole Bead Count >95% Whole Bead Count >95%
Functional Groups Polystyrene Sulphonate Functional Groups Polystyrene Sulphonate
Ionic Form (as shipped) H+ form Ionic Form (as shipped) H+ form
Shipping Weight g/l (lb/ft3) 820 (51) Shipping Weight g/l (lb/ft3) 760 (47.5)
Particle Size Range +1.2mm <5% -0.71mm <1% Particle Size Range +1.2mm <5% -0.71mm >1%
Effective Size 0.8mm Effective Size 0.8mm
Uniformity Coefficient 1.25 max Uniformity Coefficient 1.25 max
Moisture Retention H+ form (Na+ form) 47-50% (40-43%) Moisture Retention H+ form (Na+ form) 54-59% (48-53%)
Reversible Swelling (Na+H+) 5% max Reversible Swelling (Na+H+) 5% max
(NH4+H+) 4% max (NH +H+)
4 4% max
Secific Gravity Moist H+ Form (Moist Na+ Form) 1.20 (1.29) Specific Gravity Moist H+ Form (Moist Na+ Form) 1.18 (1.25)
Total Exchange Capacity Na+ form (wet volumetric) 2.0 meq/ml min Total Exchange Capacity Na+ form (wet volumetric) 1.8 meq/ml min
(dry weight) 4.4 meq/g min (dry weight) 4.4 meq/g min
Maximum Operating Temperature C (F), Na+ form 140 (285) Maximum Operating Temperature C (F) Na+ form 140 (285)
H+ form 120 (250) H+ form 120 (250)
pH Range No limitations pH Range No limitations

PUROLITE SGA-400TL PUROLITE A-500TL

(Clear Gel Type 1 Strong-Base Anion Exchange Resin) (Macroporous Type 1 Strong-Base Anion Exchange Resin)

Typical Chemical & Physical Characteristics Typical Chemical & Physical Characteristics

Polymer Matrix Structure Gel Styrene- divinylbenzene Polymer Matrix Structure Macroporous Styrene- divinylbenzene
Physical Form and Appearance Clear golden pheres Ionic Form and Appearance Pale-brown opaque spheres
Whole Bead Count >95% Whole Bead Count >95%
Functional Groups Type 1 Quaternary Ammonium Functional Groups Type 1 Quaternary Ammonium
Ionic Form (as shipped) SO - form
4 Ionic Form (as shipped) SO - form
4
Shipping Weight g/l (lb/ft3) 690 (43) Shipping Weight g/l (Ib/lt3) 680 (42.5)
Particle Size Range + 0.85 <5% -0.42mm <1% Particle Size Range + 0.85 <5% -0.42mm <1%
Effective Size 0.55mm Effective Size 0.55mm
Uniformity Coefficient 1.35 max Uniformity Coefficient 1.35 max
Moisture Retention CL- form 48-54% Moisture Retention CL- form 53-58%
Reversible Swelling (CL- OH- max) 20% Reversible Swelling (CL-OH- max) 10%
Specific Gravity CL- Form 1.08 Specifis Gravity, Moist CL- Form 1.07
Total Exchange Capacity CL- form(wet volumetric) >1.3 eq/l min Total Exchange Capacity CL- form (wet volumetric) >1.5 eq/l min
(dry weight) >3.7 eq/kg min (dry weight) >3.7 meq/g min
Max Operating Temperature C (F) CL- Form 100 (212) Max Operating Temperature C (F) CL- Form 100 (212)
OH- Form 60 (140) OH- Form 60 (140)
pH Range (Stability) 0-14 pH Range (Stability) 0-14

Page 15
638-CONDENSATE TEXT 14/6/99 10:27 am Page 18

INDEX

Subject Page

AGR power stations 3

2 Amino - 2 methyl propanol 3, 10, 11
Ammonex 7, 11
Ammonia addition 2, 3, 7, 8, 11
Attrition (resistance to) 8, 11, 12, 13
Bisulphate 5
Boilers - once through 2, 3
Boiler tubes - Corrosion of 2, 3
Cation - Anion resin separation 5
Chloride Ion Exchange 5, 11
Concentration Factors 2, 3
Condenser leakage 2, 7, 8, 9, 10
Conesep 6, 11
Contamination of Condensate 2, 6
Copper 2, 3, 10
Cross Contamination (of resin with regenerant) 5
Crud 3, 6, 10, 11, 13
D.V.B. content of Cation resin 6, 7, 8, 9, 10, 12
Filtration efficiency 10
Flow rates 4
Fouling and ageing of I.E.R. 5
Heat transfer surfaces 4
Hydrazine addition 2, 3
Interface isolation vessel 6
Iron 2, 3, 6
Inert spacer resin 6
Kinetics 4, 5, 7, 8
Microlite 10
Mixed beds 4
Morphaline 3, 9, 11
Osmotic shock 4, 9, 12, 13
pH of condensate 2, 3, 8, 11
Pre-coat filtration 2, 10, 11
Pressure Drop 4, 10, 13
PWR power stations 3
Resin separation - degree of 7, 8
Selectivity coefficient 8, 9
Seprex 7, 11
Sodium leakage 3, 5, 6, 7, 8, 9, 11
Start up 10
Sulphate ion exchange 5,11
Sulphonates 5
Treated condensate specifications 3
Tripol 7, 11, 12
Zone of exchange 5

Page 16
638-CONDENSATE TEXT 14/6/99 10:27 am Page 19

REFERENCES

1. Sadler M.A. Bates J.C., Darvill M.R. and Ellis G.W. Morpholine form condensate
polishing at Oldbury P.S. Society of Chemical Industry, Ion Exchange for Industry
Ed M. Streat, Pub, Ellis Horwood, Chichester (1988).
2. Harries R.R. & Ray N.J. Anion Exchange in high Flow Rate Mixed Beds. Effluent
and Water Treatment Journal 24, 131, Feb 1984.
3. Emmett J.R. and P.M. Grainger Ion Exchange Mechanisms in Condensate
Polishing. Proc 40th International Water Conference Pittsburgh 1979.
4. Sullivan D.J. Experience with a Conesep Condensate Polishing Plant. 8th E.P.R.I.
Condensate Polishing Workshop, Little Rock Arkansas 31st May - 2 June 1989.
5. Sadler M.A. and Bolton H.R. Regeneration of condensate Polishing Mixed Bed
Resins: A Review of 10 years Experience with the Conesep
Separation/Regeneration System. 50th Annual Meeting International Water
Conference, Pittsburgh, October 1989.
6. Smith J.H. and Peploe T.A. The TRIPOL process a new approach to ammonia
cycle condensate Polishing, Water Chemistry 11 British Nuclear Energy Society
Bournemouth 1980.
7. Harries R.R. The role of pH in ion exchange kinetics. Society of Chemical
Industry.Ion Exchange for Industry, Ed M. Streat, Pub, ellis Horwood, Chichester
(1988).
8. Crits G.J. Ion Exchange Technology, Eds, D Naden & M Streat, Pub, Ellis
Horwood Chichester (1984).
9. Frisch N & Kunin R. A.I. Chem E.J. (1960) 6,640.
10. Harries R.R. and Title K. Deterioration of Exchange Kinetics in Condensate
Purification Plant 4th conf. on Water Chemistry of Nuclear Reactor Systems,
Bournemouth 1986, British Nuclear Eng, Society London.
11. Ray M.J. Ball M. & Coates A. Kinetic Performance Tests of Anion Exchange
Resins. 42nd Int Water Conference, Pittsburgh, Penn. 1981.
12. Title K. Mixed Bed Performance in Condensate Polishing Plant Proc Amer Power
Conf. (1981) 43, pp 1126 - 1130.
13. Smith J.A. & Peplow T.A. Experimental Comparison between mixed bed and single
column anion exchange kinetics. Nato A.S.I. Mass transfer and Kinetic of Ion
Exchange Maratea, June 1982.
14. Austwald D.C. Ion Exchange for Industry Eds. M. Streat, Pub, Ellis horwood
Chichester (1988).
15. Ball M. Jenkins M.A. and Burrows R.J. Ammonium form cation resin operation of
condensate purification plant. Ion Exchange Technology. Eds Naden and M. Streat,
Pub, Ellis Horwood, Chichester (1984).
16. Harries R.R. Bates J.C. & Greene J.C. Volatile amines in the water/stream circuit:
the importance of resin choice for condensate polishing, 5th International
Conference on Water Chemistry of Nuclear Reactor Systems, Bournemouth, 1989,
British Nuclear Energy Society, London.
17. Ball M. Harries R. and Pickering the Physical Strength of Ion Exchange Resins.
Pittsburgh International Water Conference 1986.

Page 17
950-CONDENSATE COVER 14/6/99 10:23 am Page 2

SALES OFFICES & BUSINESS CENTRES:

U.S.A. ITALY
The Purolite Company, 150 Monument Road, Bala Cynwyd, Purolite International S.r.l., Viale Coni Zugna 29, 20144 Milan.
Philadelphia PA 19004. Telephone: (39) 02-481-8145 Telefax: (39) 02-4801-2359
Telephone: (1) 610-668-9090, Toll Free: 800-343-1500,
Telex: 291718, Telefax: (1) 610-668-8139. ROMANIA
Purolite Romania, International Business Centre 'Modern',
Texas
34-36 Carol I Blvd, 5th Floor, Bucharest.
The Purolite Company, 1700 West Loop South, Suite 740,
Telephone: (40) 1-250-5053/5028 Telefax: (40) 1-250-5999
Houston, TX 77027.
Toll Free: 800-562-6488, Telefax: (1) 713-627-7890
POLAND
California Radus Spolka z o.o., ul Przebendowskich 33, 81-543 Gdynia.
The Purolite Company, 22632 Golden Springs Drive, Suite 190, Telephone: (48) 58-6248979/58-6649609/58-6649617,
Diamond Bar, CA 91765. Telefax: (48) 58-6248118
Telephone: (1) 909-396-5253, Telefax: (1) 909-396-5258
CZECH & SLOVAK REPUBLICS
MEXICO Purolite International, Nad Mazankou 17, 182 00 Prague 8.
Purolite International, S.A. De C.V., World Trade Center, Telephone & Telefax: (420) 2-6881086/2-90010330
Montecito 38 Piso 33-19, Mexico City, D.F. 03810.
Telephone: (52) 5-488-0905, Telefax: (52) 5-488-0906 RUSSIA
Moscow - Head Office
CANADA Purolite International, 10th Floor, 36 Lyusinovskaya Street,
The Purolite Company, 625 Wabanaki Drive, Unit #2, Kitchener, Moscow 113093.
Ontario N2C 2G3. Telephone: (7) 502-2222120 (satellite)/ (7) 095-5648120
Telephone: (1) 519-896-6674, Toll Free: (1) 800-461-1500 Telefax: (7) 502-2222121 (satellite)/ (7) 095-5648121, (7) 095-7455047.
Telefax: (1) 519-896-6679
St. Petersburg
Purolite Interntional Limited, 12A Tabovskaya St,
UNITED KINGDOM
St. Petersburg, 192007.
Purolite International Limited, Kershaw House, Great West Road,
Telephone: (7) 812-3278530, Telefax: (7) 812-3279079
Junction with Lampton Road, Hounslow, TW5 0BU.
Sales - Telephone: (44) 181-570-4454, Telefax: (44) 181-572-7726
UKRAINE
European Marketing - Telephone: (44) 181-577-1222, Purolite International Limited, 2 Korolenko Street,
Telefax: (44) 181-577-1136 Dnepropetrovsk 320070.
Telephone: (38) 0562-320065/66, Telefax: (38) 0562-320067
GERMANY
Purolite Deutschland GmbH, Harkortstrasse 25, 40880 Ratingen. KAZAKHSTAN
Telephone: (49) 2102-46033, Telefax: (49) 2102-443663 Purolite RH Limited, Office 25, 157 Abaya ave., Almaty, 480009.
Telephone: (7) 3272-608-449, Telefax: (7) 3272-509-475.
FRANCE
Purolite International SARL, 34 Avenue Matignon, 75008 Paris. CHINA
Telephone: (33) 1-42-564563, Telex: 648856, Telefax: (33) 1-45-633826 Purolite (China) Limited, Chenguan County, Dequin City,
Xhejiang Province, 313200.
BELGIUM Telephone: (86) 572-8422908/8422819, Telefax: (86) 572-8423954
Purolite Benelux, Industrieweg 11 - Zinkval, 2630 Aartselaar (Antwerp).
Telephone: (32) 3 -870-7298, Telefax: (32) 3-870-7299 SINGAPORE
Purolite International (Singapore) PTE Limited,
SPAIN 32-04 The Concourse, 300 Beach Road, 199555.
Purolite Iberica S.A., Parc Tecnologic del Valles, Centre Telephone: (65) 297-0889/297-1453, Telefax: (65) 297-1986
Empreses Noves Tecnologies, 08290 Cerdanyola del Valles
(Barcelona). TAIWAN
Telephone: (34) 93-582-0266, Telefax: (34) 93-582-0268 Purolite International, 16F-2, No. 191, Fu-hsing N. Road, Taipei.
Telephone: (886) 2-546-7078, Telefax: (886) 2-546-7069
EGYPT
Purolite International Middle East, LCC KOREA
12 Obour Gardens, 5th Floor, App. No. 55, Saleh Salem Street, Purolite International (Korea) LLC, Dae Yeon Bldg., Suite 403,
Nasr City, Cairo. 943-30 Daechi-dong, Kangnam-gu, Seoul.
Telephone: (20) 2-4031969, Telefax: (20) 2-4021478 Telephone: (82) 2-3453-7062/7063, Telefax: (82) 2-3453-7064

SWEDEN
Purolite Nordiska AG, Hjdrodergatan 5, 21 239 Malm.
Telephone: (46) 40-292130, Telefax: (46) 40-292232

Web Site. http://www.purolite.com

The Purolite Company and Purolite International Limited have one of the most complete ranges of ion exchange resins worldwide. For further information please
contact your local Purolite office.
All suggestions and recommendations given concerning the use of Purolite products are based on tests and data believed to be reliable. However, as
Purolite cannot control the use of its products by others, no guarantee is either expressed or implied by any such suggestion or recommendation by
Purolite nor is any information contained in this bulletin to be construed as a recommendation to infringe any patent currently valid.
Produced by Hamilton-Rio Design, Epsom, U.K.
Printed in England
10/98